Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Fuel/propulsion System. Review the 47 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Fuel System, Diesel. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

5 crash reports11 fire reports1 injury reports

Fuel/propulsion System complaints

47 reports

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153,000 miles · Jun 4, 2019

Fuel/propulsion System

WHEN CAR WAS IN MOTION IT SPUTTERED, STARTED LOSING POWER, AND WHEN I PULLED OVER THE ENGINE DIED AND WOULDN'T RESTART. DEALER DIAGNOSED IT AS FAILURE OF FUEL PUMP, WITH BMW REQUIRED REPAIR TO INCLUDE REPLACEMENT OF ENTIRE FUEL DISTRIBUTION SYSTEM AT ESTIMATED COST OF $11,400

NHTSA ODI #11217811

Mileage unknown · Mar 22, 2019

EngineFuel/propulsion System

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EXHAUST GAS RECIRCULATION (EGR) COOLER RECALL: CONTACTED BMW CUSTOMER RELATIONS AS PER RECALL LETTER FROM BMW OF N.A. VIA EMAIL AND THEY LEFT A VOICE MAIL THAT PARTS HAVE NOT BEEN AVAILABLE. RECALL STATUS ALSO HAS BEEN STATING - "REMEDY NOT YET AVAILABLE". RECALL WAS MADE IN OCT 25, 2018 AND IT IS NEARING 6 MONTHS BUT NO SOLUTION OR REPAIR PROCESS HAS BEEN INITIATED. LETTER STATES POSSIBILITY OF INCREASED RISK OF FIRE COULD OCCUR IF ENGINE INTAKE MANIFOLD HAS SMALL HOLES DUE TO FAILURE OF EGR. KINDLY PLEASE HELP WITH THIS UNTIMELY AND UNREASONABLE TIME PERIOD OF REPAIR LINGERING WITHOUT ANY SAFETY FOR THE DRIVER OF THIS CAR. CURRENTLY NO PROBLEM HAS OCCURRED BUT FEELING OF DRIVING ON BORROWED LUCK AND TIME IS NOT A SAFE ONE. THANK YOU FOR YOUR HELP.

NHTSA ODI #11191014

64,917 miles · Oct 3, 2018

EngineFuel/propulsion SystemVehicle Speed Control

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WHILE DRIVING AT 65 MPH OR SO THE VEHICLE'S ON-BOARD MESSAGE CENTER READ "DRIVE-TRAIN MALFUNCTION". I PRESSED ON THE ACCELERATOR AND THERE WAS NO RESPONSE. THE VEHICLE WAS LOOSING MOMENTUM QUITE QUICKLY WHICH REQUIRED ME TO SWIFTLY, BUT SAFELY TO PULL OVER TO THE ROADWAY EDGE. THIS IS THE THIRD TIME THE ISSUE HAS PRESENTED ITSELF. THE FIRST TIME WAS A FEW MONTHS FROM PURCHASING THE VEHICLE. THE DEALER FOUND METAL SHAVINGS IN THE FUEL LINES. THEY REPLACED THE ENTIRE FUEL SYSTEM AND SENT ME OFF. A FEW MONTHS LATER I TOOK THE VEHICLE IN FOR SERVICE I.E. OIL CHANGE, INSPECTION, ETC. WHILE INSPECTING MY CAR THEY AGAIN FOUND METAL SHAVINGS IN THE FUEL LINES. THEY AGAIN REPLACED THE ENTIRE FUEL SYSTEM AND SAID IT WAS FIXED. JUST THIS WEEKEND SEPTEMBER 30, 2018, I WAS DRIVING MY VEHICLE ON THE FREEWAY AND AGAIN THE CAR WENT LIMP. NO POWER, LIMITED STEERING CONTROL, NO RESPONSE FROM ACCELERATOR. ESSENTIALLY A CATASTROPHIC EVENT BECAUSE WITHOUT POWER A VEHICLE IS A ROLLING PROJECTILE. ACCORDING TO THE DEALERSHIP THE VEHICLE ONCE AGAIN HAS METAL SHAVINGS IN THE FUEL SYSTEM. TOTAL COUNT FOR REPLACING FUEL SYSTEM (3).

NHTSA ODI #11133035

30,000 miles · Apr 30, 2018

Fuel/propulsion SystemCrash

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MARCH 6, 2018, MY CAR STARTED SHAKING AS I MERGED FROM 101 TO 405 S IN LOS ANGELES. MESSAGE INDICATED A DRIVE TRAIN PROBLEM AND TO "DRIVE MODERATELY". CAR STOPPED AND WOULD NOT RESTART SECONDS LATER. WHILE WAITING FOR A TOW, WAS REAR ENDED AT A DEAD STOP. BMW SANTA MONICA FOUND METALS SHAVINGS IN FUEL LINE AND REPLACED FUEL SYSTEM; MY CAR ALSO HAD $13,000 OF BODY DAMAGE. I HAVE SEEN MANY OTHER REPORTS OF THE SAME PROBLEM - BMW SHOULD HAVE RECALLED THE CAR TO FIX THE FUEL SYSTEM BEFORE I HAD AN ACCIDENT. NOW MY CAR IS DEVALUED AND I DO NOT HAVE SAME LEVEL OF CONFIDENCE IN DRIVING IT.

NHTSA ODI #11090994

39,900 miles · Mar 29, 2018

EngineFuel/propulsion System

WITHOUT ANY WARNING, THE VEHICLE LOST POWER SUDDENLY/ ABRUPTLY STOPPED ON A BUSY CITY STREET. THE VEHICLE ALMOST GET SLAMMED INTO BY OTHER VEHICLES TRAVELING BEHIND IT. THIS WAS POTENTIALLY A CAUSE FOR A FATAL ACCIDENT. BMW DEALERSHIP INFORMED THAT THE CAUSE WAS THE SUDDEN FAILURE OF THE FUEL PUMP. VEHICLE IS AT 39,900 MILES, &…

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NHTSA ODI #11082066

45,000 miles · Mar 9, 2018

Fuel/propulsion SystemInjury

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WHILE ACCELERATING MY 2014 BMW 328D I HEARD A GRINDING NOISE AND THE CAR HIT THE BRAKES SO HARD THAT THE SEAT BELT PINNED ME AGAINST THE SEAT AND MY CHEST HURT AFTER THAT FOR A COUPLE DAYS. I CALLED BMW ROADSIDE AND THE POLICE TO ASSIST WITH TRAFFIC SINCE I WAS IN THE MIDDLE OF THE ROAD, WAS LATE EVENING AND RAINING ALSO. THE POLICE OFFICER TRIED TO MOVE THE CAR BUT THE WHEELS WERE LOCKED AND WAS UNABLE TO PUT IT IN NEUTRAL OR MOVE. WHILE GETTING OUT OF CAR HE TELLS ME THAT I AM LUCKY IN HIS OWN WORDS "ON THIS WEATHER ON THE FREEWAY YOU WOULD'VE BEEN DEAD BY NOW". ALSO THE TOW TRUCK DRIVER HAD THE SAME LINE AS THE OFFICER AND HE DRAGGED THE CAR ON THE BED SINCE THE WHEELS WERE LOCKED. THE CAR WAS TAKEN TO THE DEALER AND BMW DIAGNOSED IT AS "FUEL PUMP BLEW UP INTERNALLY AND DISTRIBUTED METAL SHAVINGS THROUGHOUT THE ENTIRE FUEL SYSTEM AND THROUGH INJECTORS." 4 INJECTORS NEED REPLACEMENT ALONG WITH THE FUEL RAIL, THE FUEL PUMP AND REPAIRS MADE TOT THE ENTIRE FUEL SYSTEM INCLUDING THE TANK. BMW WILL COVER EVERYTHING SINCE THE CAR IS STILL UNDER WARRANTY ( I AM AT 45 K MILES)! MOST TRAUMATIZING EXPERIENCE OF MY 40 YEARS LIFE IN A 50K+ CAR! BMW NEVER WARNED ME OF POSSIBLE FUEL PUMP FAILURE PROBLEM WITH THEIR DIESEL CARS AND NO CAR SHOULD PIN YOU WITH THE SEAT BELT AGAINST THE SEAT UNLESS IT'S AN ACCIDENT!

NHTSA ODI #11078257

Mileage unknown · Nov 22, 2017

Fuel/propulsion System

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I WAS DRIVING HOME FROM WORK ON NOVEMBER 16TH AND WAS WITHIN A COUPLE MILES OF MY HOUSE WHEN I HEARD A LOUD BANG AND A WHIRRING SOUND COMING FROM MY CAR. THERE WAS AN ERROR MESSAGE THAT POPPED UP STATING DRIVETRAIN MALFUNCTION, DRIVE CAUTIOUSLY.' THE CAR BECAME VERY JERKY AND I DROVE SLOWLY. I WAS FORTUNATE TO MAKE IT BACK TO MY DRIVEWAY, BUT THEN MY CAR COMPLETELY FAILED. I HAD THE CAR TOWED TO THE DEALERSHIP AND THE CALLED TO LET ME KNOW THE TRANSFER CASE HAD FAILED. THANKFULLY I WASN'T INJURED IN A CAR WRECK WHEN THE IT FAILED. THE CAR ONLY HAD ABOUT 46,500 MILES AND WAS COMPLETELY COVERED UNDER WARRANTY. I WAS FORTUNATE TO GET HOME, BUT A COMPLETE FAILURE COULD HAVE LED TO BEING STRANDED OR WORSE, AN ACCIDENT.

NHTSA ODI #11048113

66,000 miles · Nov 5, 2017

Fuel/propulsion System

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WHILE DRIVING DOWN THE INTERSTATE ON OCT. 22, 2017 MY VEHICLE TURNED OFF IN THE MIDDLE OF THE ROAD DISPLAYING AN ERROR SAYING "DRIVE TRAIN MALFUNCTION". THE CAR WENT FROM GOING 60MPH TO A DEAD STOP. I WAS STRANDED IN THE ROAD WHILE CARS WERE ZIPPING PAST ME AT LEAST 60MPH. I WAS IN SOME SERIOUS DANGER IF IT WASN'T FOR THE FAST RESPONSE OF THE TOW TRUCK TO GET ME OUT OF THERE (THE POLICE WERE CALLED AS WELL TO DO TRAFFIC CONTROL BUT THE TOW TRUCK SHOWED UP BEFORE THEY EVEN GOT THERE). THE VEHICLE WAS TOWED TO A BMW DEALER. THEY RAN SOME TESTS AND TOLD ME IT WAS A FUEL PUMP PROBLEM. THEY SAID THE FUEL PUMP BROKE INTERNALLY AND DISTRIBUTED METAL SHAVINGS THROUGHOUT MY ENTIRE FUEL SYSTEM AND THROUGH MY INJECTORS. ALL 4 INJECTORS NEED REPLACED ALONG WITH THE FUEL RAIL AND THE FUEL PUMP AND REPAIRS MADE TOT THE ENTIRE FUEL SYSTEM. MY CAR IS ONLY AT 66K MILES. I DID SOME RESEARCH TO SEE IF THIS PROBLEM WAS RECALLED BECAUSE THIS IS A VERY UNSAFE PROBLEM TO HAVE. AFTER LOOKING, I SAW THAT A RECALL WAS SENT OUT FOR ALL BMW MODELS EXCEPT FOR THE 328D(DIESEL). WHY IS THAT? HOW DO YOU CLAIM SOMETHING IS UNSAFE ON A CAR USING THE SAME PARTS THAT JUST GOT RECALLED BUT EXCLUDED THE DIESEL MODEL. I HAVE READ SOMETHING STATING THERE WAS NOT ENOUGH COMPLAINT TOWARDS THE DIESEL MODEL BUT THE 328D WAS NOT PRODUCED NEARLY AS MUCH AS SAY THE 328I, SO OBVIOUSLY IT WILL HAVE FEWER COMPLAINTS. I CAN SEE RIGHT NOW 5 PAGES OF COMPLAINTS ABOUT THE SAME SAFETY ISSUE I AM HAVING THAT SAYS OTHERWISE. NOW I AM PAYING UPWARDS OF $16,000 DOLLARS DUE TO A SAFETY ISSUE. THIS DOESN'T SEEM ETHICALLY CORRECT ON ANYONE'S END. HOW IS THERE NO RESOLUTION TO THIS PROBLEM? WE ARE GOING TO LET PEOPLE COME TO A COMPLETE STOP ON THE INTERSTATE AN RISK A MAJOR ACCIDENT. I CAN'T BELIEVE THIS HAS SLIPPED THROUGH THE CRACKS WHEN ALL OTHER MODELS WERE RECALLED FOR THE EXACT SAME PROBLEM!!

NHTSA ODI #11043366

110,000 miles · Oct 18, 2017

Fuel/propulsion System

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HIGH PRESSURE FUEL PUMP FAILED CAUSING CATASTROPHIC DAMAGE TO ENTIRE FUEL SYSTEM, REQUIRING REPLACEMENT OF ENTIRE FUEL SYSTEM INCLUDING FUEL PUMPS, FUEL LINES, TANK ETC. STALL OCCURRED ON BUSY STREET WHICH WAS A NEAR DEATH EXPERIENCE THAT COULD HAVE RESULTED IN ACCIDENT / INJURY / DEATH. MOST TERRIFYING EXPERIENCE OF MY LIFE. TOOK CAR TO CREVIER BMW AND DEALER STATED THAT THERE WAS NOTHING I COULD HAVE DONE TO PREVENT THE INCIDENT. 2014 2 SERIES, 3 SERIES, AND 4 SERIES ALL HAVE BEEN RECALLED FOR HIGH PRESSURE FUEL PUMP FAILURE. THE DIESEL MODEL APPEARS TO BE THE ONLY ONE NOT COVERED IN THE RECALL AND CLEARLY IS DEFECTIVE.

NHTSA ODI #11034439

50,000 miles · Jul 25, 2017

EngineFuel/propulsion System

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TL* THE CONTACT OWNS A 2014 BMW 328D. WHILE DRIVING 50 MPH AND SLOWING DOWN TO MAKE A TURN, THE VEHICLE SUDDENLY LOST ALL POWER AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TOWED TO STEVE THOMAS BMW INC (411 E DAILY DR, CAMARILLO, CA 93010 (805) 482-8878) WHERE IT WAS DIAGNOSED THAT THE HIGH PRESSURE FUEL PUMP FAILED AND RELEASED METAL SHAVINGS INTO THE FUEL SYSTEM AND ENGINE. THE FUEL SYSTEM NEEDED REPLACEMENT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE CONTACT RESEARCHED ONLINE AND FOUND NHTSA CAMPAIGN NUMBER: 15V189000 (FUEL SYSTEM, GASOLINE), BUT THE VIN WAS NOT INCLUDED. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000.

NHTSA ODI #11010637

Official recalls

24V527000 · Air Bags:frontal:driver Side:inflator Module

Jul 11, 2024

BMW of North America, LLC (BMW) is recalling certain 2015 6 Series Gran Coupe, 2014 5 Series Gran Turismo, 2014 5 Series Sedan, 2015 6 Series Convertible, 2015 6 Series Coupe, 2014 X5, 2013-2014 X3, 2014-2015 3 Series Sedan, 2014 4 Series Coupe, 2014 4 Series Convertible, 2014 3 Series Gran Turismo, and 2015 4 Series Gran Coupe vehicles. Please see the recall report for the complete list of models. The driver's air bag inflator may explode during deployment, due to a manufacturing defect.

Consequence & remedy

Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, increasing the risk of injury or death.

Remedy: The driver's front air bag will be replaced, free of charge. Owner notification letters were mailed September 6, 2024. Owners may contact BMW customer service at 1-800-525-7417.

24V288000 · Air Bags:side/window

Apr 24, 2024

BMW of North America, LLC (BMW) is recalling certain 2014-2015 2 Series Coupe (228i, 228i xDrive, M235i), 3 Series Sedan (320i, 320i xDrive, 328i, 328i xDrive, 335i, 335i xDrive, M3, 328d, 328d xDrive), 4 Series Coupe (428i, 428i xDrive, 435i, 435i xDrive, M4), and 2015 4 Series Gran Coupe (428i, 428i xDrive, 435i, 435i xDrive) vehicles. The head air bag inflator may fail at the weld joint, which can cause gas to leak from the inflator or result in an inflator rupture.

Consequence & remedy

Consequence: An inflator that ruptures may cause sharp metal fragments to enter or exit the vehicle, increasing the risk of injury. Additionally, an inflator that leaks gas may only partially inflate during a crash, increasing the risk of injury.

Remedy: Dealers will replace the head air bags, free of charge. Owner notification letters were mailed November 4, 2024. Owners may contact BMW customer service at 1-800-525-7417.

21V907000 · Fuel System, Diesel

Nov 19, 2021

BMW of North America, LLC (BMW) is recalling certain 2013-2018 328d, 328d xDrive, 2014-2018 328d Sports Wagon, 328d xDrive Sports Wagon, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV, and 2014-2017 X5 xDrive35d SAV diesel vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. The EGR cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake manifold.

Consequence & remedy

Consequence: A melting intake manifold increases the risk of a fire.

Remedy: Dealers will replace the EGR cooler and inspect the intake manifold, replacing it as necessary, free of charge. This recall includes all vehicles previously recalled under 18V-755. Vehicles previously recalled under 18V-755 will need to have the new remedy performed for this recall. An interim owner notification letter was mailed on January 18, 2022. The remedy is expected to be available in June 2022. Owner notification letters were mailed on July 6, 2022. Owners may contact BMW customer service at 1-800-525-7417.

21V586000 · Fuel System, Diesel:delivery:fuel Pump

Jul 29, 2021

BMW of North America, LLC (BMW) is recalling certain 2014-2018 328d, 328d xDrive, X5 xDrive35d, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, and 2015-2017 X3 xDrive28d vehicles. The high-pressure fuel pump may fail.

Consequence & remedy

Consequence: Fuel pump failure can cause an engine stall while driving, increasing the risk of a crash.

Remedy: Dealers will replace the high-pressure fuel pump, free of charge. Owner notification letters were mailed on January 14, 2022. Owners may contact BMW customer service at 1-800-525-7417.

20V185000 · Power Train:driveline:constant Velocity Joint

Mar 26, 2020

BMW of North America, LLC (BMW) is recalling certain 2013-2016 328d xDrive sedans and 2013-2015 328d xDrive station wagon vehicles. The constant-velocity joint which transfers power between the transfer case and the rear drive shaft, may become damaged, possibly resulting in loss of power to the rear wheels.

Consequence & remedy

Consequence: A loss of power to the rear wheels can affect vehicle control, increasing the risk of a crash. Additionally, when the vehicle is parked after a loss of power to the rear wheels and the parking brake is not engaged, unintended rollaway can occur, increasing the risk of a crash or injury.

Remedy: BMW will notify owners, and dealers will replace the constant-velocity joint and inspect the transfer case, replacing it if necessary, free of charge. The recall began May 22, 2020. Owners may contact BMW customer service at 1-800-525-7417.

18V755000 · Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve)

Oct 25, 2018

BMW of North America, LLC (BMW) is recalling certain 2013-2018 BMW 328d and 328d xDrive, 2014-2018 328d Sports Wagon and 328d xDrive Sports Wagon, 2014-2016 535d and 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV and 2014-2017 X5 xDrive35d SAV vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold.

Consequence & remedy

Consequence: The melting intake manifold can increase the risk of a fire.

Remedy: BMW will notify owners, and dealers will inspect and replace the EGR cooler as necessary. If a leak has already occurred, the engine intake manifold will also be replaced. These repairs will be made free of charge. The recall began May 13, 2019. Owners may contact BMW customer service at 1-800-525-7417.

15V520000 · Exterior Lighting

Aug 17, 2015

BMW North America, LLC (BMW) is recalling certain model year 2012-2015 320i, 320xi, 328i, 328xi, 335i, 335xi, and ActiveHybrid3 vehicles manufactured October 20, 2011, to June 22, 2015, 2014-2015 328xi Sports Wagon vehicles manufactured March 21, 2013, to March 17, 2015, 2014-2015 328d, 328xd vehicles manufactured June 28, 2013, to April 21, 2015, and 2014-2015 328xd Sports Wagon vehicles manufactured July 5, 2013, to April 21, 2015. The affected vehicles may have been programmed with new software that inadvertently makes the front side marker lights inoperative in conjunction with the parking lights or the headlights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: If the side marker lights do not illuminate, the vehicle may be less visible at night, increasing the risk of a crash.

Remedy: BMW will notify owners, and dealers will upload revised software to correct the issue, free of charge. The recall began on October 7, 2015. Owners may contact BMW customer service at 1-800-525-7417 or by email at CustomerRelations@bmwusa.com.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

EA23001 · High Pressure Fuel Pump Failure

Opened Mar 17, 2023 · No close date supplied

Status: open (inferred from source dates) · Fuel System, Diesel:delivery:fuel Pump

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337

EA21002 · Desiccated Air Bag Inflator Rupture

Opened Sep 17, 2021 · No close date supplied

Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Additional source detail variants (2)

Air Bags:frontal:driver Side:inflator Module

Air Bags:frontal:passenger Side:inflator Module